Photovoltaic module mounting system and method

ABSTRACT

A photovoltaic (PV) module mounting system can have mounting clips that can be moved up and down a roof, and can allow the height of the mounting clips to be adjusted relative to the roof. At least a portion of the system can be made of a non-conductive material so that the system can be free of a grounding unit. The system can allow solar modules to be quickly installed, and can allow the solar modules to be removed quickly for repair or in the event of a fire.

RELATED APPLICATION

This application is a continuation of co-pending U.S. patent applicationSer. No. 16/024,155, entitled PHOTOVOLTAIC MODULE MOUNTING SYSTEM ANDMETHOD, filed Jun. 9, 2018, which claims the benefit of U.S. ProvisionalApplication Ser. No. 62/526,932, entitled PHOTOVOLTAIC MODULE MOUNTINGSYSTEM AND METHOD, filed Jun. 29, 2017, the teachings of each of whichapplications are expressly incorporated herein by reference.

FIELD OF THE INVENTION

This invention relates to solar photovoltaic (PV) modules and systemsand the attachment of such systems to building rooftops.

BACKGROUND OF THE INVENTION

As mankind continues to develop around the world, the demand for energyrises. Most energy used to power machines and generate electricity isderived from fossil fuels, such as coal, natural gas or oil. Thesesupplies are limited and their combustion causes atmospheric pollutionand the production of carbon dioxide, which is suspected to acceleratethe greenhouse effect and lead to global climate change. Somealternative approaches to produce energy include the harnessing ofnuclear energy, wind, moving water (hydropower), geothermal energy orsolar energy. Each of these alternative approaches has drawbacks.Nuclear power requires large capital investments and safety and wastedisposal are concerns. Wind power is effective, but wind turbinesrequire a windy site, often far away from grid connections and take uplarge footprints of land. This energy production system also requirescontinual mechanical maintenance, and can have an impact on theaesthetics of the surroundings and wildlife. Hydropower requires theconstruction of large, potentially environmentally harmful dams and thedisplacement of large volumes of flowing water. The number of suchflowing water bodies is highly limited, both regionally and in anabsolute sense. Geothermal power requires a source of energy that isrelatively near the surface—a characteristic not common to a largeportion of the Earth—and has the potential to disrupt the balance offorces that exist inside the Earth's crust. However, solar is one of thecleanest and most available forms of renewable energy and it can beharnessed by direct conversion into electricity (solar photovoltaic) orby heating a working fluid (solar thermal).

Solar photovoltaic (PV) technology relies on the direct conversion ofsolar power into electricity through the photoelectric effect in a solarcell: solar radiation impinging on semiconductor junctions can excitepairs of conduction electrons and valence holes. These charged particlestravel through the junction and can be collected at electricallyconductive electrodes to form an electric current in an externalcircuit. A PV module can include at least one solar cell that can be apart of a solar laminate, and can include a supporting frame. A solarlaminate can have at least one solar cell between two layers ofencapsulant. A PV module can also have a supportive backing under thesolar laminate and connected to the frame to provide additional supportfor the solar laminate.

Photovoltaic is one of the most promising technologies for producingelectricity from renewable resources, for a number of reasons: (1) Thephotovoltaic effect in Si and other solid-state semiconductors is wellunderstood and the technology fully validated; (2) PV power modulesconvert solar power directly into electrical power, have no moving partsand require low maintenance, and can be located on almost any surfacedue to relatively light weight and thin profile; (3) Solar radiation isquite predictable and is at a maximum during hours of peak electricityconsumptions; and (4) The industry has been aggressively pursuing aperformance improvement and cost reduction path, approaching marketcompetitiveness with traditional energy resources in many parts of theworld.

There are two measures of value to the customer that is utilized in theindustry. The first is the installation cost of the system. The metricthat is most widely used for comparison is the total system cost dividedby the name plate power of the system in Watts. The unit for this metricis $/W. The second measure is the cost of energy delivered over thelifetime of the system. This is referred to as the Levelized Cost ofEnergy or LCOE. LCOE in dollars per kilowatt-hour ($/kWh) is calculatedby dividing the system cost and maintenance costs by the energy producedby the system during its expected life. Customers decide whether or notto convert to solar energy based on LCOE and decide which vendor to usebased in $/W. It is thus desirable to reduce both metrics.

As the price of photovoltaic (PV) modules continues to fall, the cost ofownership (both in terms of $/W and $/kWhr) of a PV system isincreasingly being dictated by the so-called balance of system costs.For a rooftop installed PV system, these include the following specificitems:

1. Power management hardware: These include parts such as inverters,optimizers and rapid shutdown electronics.

2. System installation hardware: All the racking, mounting, roofattachment, skirting, nuts and bolts, and other pieces of hardware thatare required to secure the PV modules to a roof.

3. Labor costs: These include the labor to install the systeminstallation hardware, attach the PV modules to the hardware, theelectrical wiring of the PV modules to each other and to the powermanagement hardware, the integration of proper grounding to all exposedmetal and the upgrading of the roof if required.

4. Permitting: The act of receiving a permit from the town to operatethe PV system. This requires adherence to local and national codes,including fire and electrical codes. Furthermore these systems mightneed sign-off from professional engineers, fire marshals and otherprofessionals.

5. Supply chain logistics: The cost of keeping inventory of multipleparts, issuing, storing and carrying all these parts onto the roof.Ensuring that parts and personnel expertise match at the site etc.

6. Indirect Costs: Operating equipment such as vehicles, ladders, liftsand tools. Administrative costs such as payroll, insurance, warrantyservicing, and management.

7. Cost of sales: This includes marketing and sales; the time and effortrequired to identify and obtain the customer. The cost of sale is oftenindependent of the size of the system.

The first two items (1 and 2) on the list above are direct materialcosts to the system, while items 3 and 4 are direct costs, and items 5,6 and 7 are considered overhead. This means that items 1 through 4typically scale with the size of the system where items 5 and 6 areindependent of the size of the system.

From the above it will be clear that it is desirable to minimize boththe direct labor and material cost of any system in order to reduce theoverall cost of the system and therefore increase the probability ofselling and installing a system. In addition, minimizing the costs ofeach installed system will directly reduce the overhead costsattributable to each system. Furthermore, increasing the size of theinstalled system will proportionally reduce the indirect cost of thesystem.

Rooftop PV systems can be installed using a variety of existing mountinghardware. Existing mounting solutions can generally be categorized as“railed” or “rail-less”. As the descriptive name indicates, the formerincludes long beams, or “rails”, typically made of aluminum metal, thatprovide support to the array of modules. The rails are especiallyrequired in regions where the solar modules can be exposed to heavy snowloading because the module construction is not adequate to support theadditional weight of the snow. The rail-less systems offeredcommercially by companies such as Pegasus Solar and Zepp have gainedmarket traction because of the ease with which they can be installed.This reduces the installation time and therefore direct labor of thesystem. However, these systems cannot be used in regions of heavy snowor wind loading because they do not provide the additional structuralsupport necessary to meet local codes and requirements. Both the railedand rail-less systems are attached to the roof using a large number(typically 30-50) of individual metal parts, including bolts, nutswashers, multi-part clamps and brackets, as described in U.S. Pat. No.9,800,199, titled ROOF ATTACHMENT ASSEMBLY FOR SOLAR PANELS ANDINSTALLATION METHOD, U.S. Pat. No. 9,496,820, titled PHOTOVOLTAICMOUNTING SYSTEM AND DEVICES, U.S. Pat. No. 9,473,066, titled MOUNTINGASSEMBLIES FOR SOLAR PANEL SYSTEMS AND METHODS FOR USING THE SAME, andU.S. patent application Ser. No. 14/054,807, the entire disclosures ofwhich are incorporated herein as background information.

Although rail-less systems can be installed more quickly, current artunfortunately only teaches rail-less systems that cannot withstand allrequired snow and wind loads experienced around the world. Currentoptions to increase load capabilities is to either increase thethickness of the module glass, or increase the stiffness of the mountingframe or utilize a framed system that mounts the PV module in such a waythat high snow load conditions do not cause failure in the PV modulecomponents. These solutions come with the burden of added weight, sizeand installation time as will be known to those skilled in the art.

The use of metallic parts, in combination with the aluminum exteriorframe that is part of a standard PV module construction leads to therequirement to electrically ground the rooftop PV system. Groundingoften requires heavy copper cable that must be connected to a copper roddriven into the ground at the foundation of the building. Grounding isusually required to be done by a licensed electrician, furtherincreasing both hardware and labor costs.

Overhead and indirect cost are not dependent on system size andcontribute a significant portion of the total cost of the system.Cost-of-sales, or the cost of identifying and acquiring the customer,can be the single largest overhead item in a smaller, residentialinstallation. Therefore it will be desirable not only to reduce theindirect costs by making the system easier to sell for instance, but itis also desirable to sell and install the largest possible system percostumer. Additionally it is desirable to make the installation processas efficient as possible. For example, doubling the speed ofinstallation would allow the same installation crew to generate abouttwice as much revenue, reducing the fixed overhead cost allocated toeach system by 50%, providing significant operating leverage for theinstaller.

A PV module can include a solar laminate that includes at least onesolar cell, a supporting backing under the solar laminate, and asupporting frame around the perimeter of the PV module. The majority ofsolar PV modules utilize an electrically conductive aluminum frame thatsurrounds the entire module. This frame serves as a structuralenforcement that assists the glass front face of the module to protectthe fragile solar cells from the environment, including structural loadsfrom wind and snow accumulation. The frame also serves as the interfacebetween the module and the mounting system that secures it to a roof orthe ground in an existing PV installation system.

Mounting systems that are structurally attached to the roof aretypically made from conductive metal. The mounting systems typicallyconsist of a multitude of parts that allow the installer of the systemto connect the system to the rafters of the house or to a metal roofcovering, provide structural stability, secure the module to the roofand provide the ability to adjust the installation so that itaesthetically aligns with features of the roof.

As can be appreciated by those skilled in the art, there are a number ofdeficiencies with current PV module mounting systems. These can besummarized as follows:

1. Exposed metal on the modules require the modules as well as themounting system to be grounded. This requirement has the drawback that ameans of electrical conductivity must be established between the moduleframe and the earth ground. This increases the amount of material andlabor required for a PV installation and thus the cost. Furthermore, thenew NEC 2017 electrical code requires that all grounded PV systems havea means of rapid shutdown that disconnects the modules from each otherelectrically. These rapid shutdown systems are costly and take time toinstall, further driving up direct costs to the PV system. In addition,the voltages in modules are increasing to reduce power loss in theconducting wires. Having cells at high voltage while the frame is atground is the driving force for Potential Induced Degradation (PID), amajor contributor to the gradual loss in power generation capacity of aPV module

2. Mounting systems require a significant amount of assembly on the roof

3. Mounting systems require precision layout, measuring and attachmentto the roof

4. Rail-less systems reduce the amount of assembly steps and thusdecrease the time of installations. However, when utilized inconjunction with standard modules, they cannot withstand high snow andwind load conditions.

5. The large number of parts of mounting systems require significantresources to maintain inventory, schedule deliveries and issue parts tocrews going to the job-site. This logistic burden increases the indirectcosts of systems.

6. Inability to release the module from the roof without proper toolsincreases the time to repair units and can obstruct firefighters fromperforming their duties.

SUMMARY OF THE INVENTION

The present invention overcomes these deficiencies of the prior art byreducing the part count on the roof, eliminating the need for groundingthe modules, providing flexibility in position adjustment after securingthe modules on the roof, and allowing for rapid release of the modulefor maintenance or firefighting operations. Additionally, utilizingfunctional, non-metallic composite materials that are electricallyinsulating for the structural security and mounting of photovoltaic (PV)modules has a number of advantages that have not been appreciated andapplied in prior art.

The present invention also addresses a multiplicity of theabove-described disadvantages that drive installer cost in order toenable lower system cost and broader penetration of rooftop solar intothe energy market, fundamentally benefitting both the solar powerindustry and the global environment. The invention described in thisapplication aims to overcome the deficiencies of the prior art byreducing or eliminating rooftop assembly of a large number of mountinghardware parts, and can minimize layout and installation precision byproviding substantial adjustability in and out of the plane of the roofand adjustability up and down the slope of the roof, and can utilizehardware clips onto the module at any point for cross-slopeadjustability. The system can allow the ability to adjust height aftermodules are installed on the mounting hardware. The system can alsoeliminate the need to ground the PV array by utilizing compositematerials for the PV module frame and the mounting hardware, and canreduce the time and material cost associated with grounding modules andeliminate the need for rapid-shutdown devices as required by NEC 2017.The system can also enable a rail-less design that can be certified forhigh snow load conditions, and can provide a quick release mount thatallows fast module replacement and easy dismount for emergency (fire)access. This will allow the array to fill the entire roof, increasingthe size of the system. The present disclosure can provide a system ofrail-less PV module mounting that can increase resistance to snow loadsby providing a displacement restrictor that can allow a rail-less systemto withstand high snow loads.

In an embodiment, a solar module installation system can include amounting base and a mounting post, wherein the mounting post isadjustably engaged with the mounting base so that the height of themounting post with the mounting base is variable, and at least onemounting clip attached to the mounting post. The system can include anadjustable foot that defines a channel configured to receive themounting base. The mounting base can include at least one baseengagement feature, and the adjustable foot can include at least onefoot engagement feature, so that the base engagement feature and thefoot engagement feature can secure the mounting base to the adjustablefoot. The at least one foot engagement feature can be at least one footsnap-in groove, and the at least one base engagement feature can be atleast one snap-in groove. The adjustable foot can include at least oneclip-in groove configured to slideably engage the mounting base, whereinthe clip-in groove slidably holds the mounting base out of engagementwith the at least one foot snap-in groove, and wherein an application offorce to the mounting base can push the mounting base out of engagementwith the clip-in groove an into engagement with the at least one footsnap-in groove. The system can also have a flashing with a flashingengagement feature, wherein the flashing engagement feature isconfigured to engage the flashing with the adjustable foot. The flashingengagement feature can be a clearing hole, and the adjustable foot canhave a bolt hole, so that a bolt can be passed through the adjustablefoot and the flashing. The system can include at least one pin, whereinthe at least one mounting clip can be pivotably mounted to the mountingpost at the at least one pin. The system can include a mounting clipwith a screw head cavity, wherein the screw head cavity can beconfigured to hold a screw head within the screw head cavity, andwherein the mounting base can include a threaded screw engagementfeature. The system can include an adjustment screw with a screw head,so that the screw head can be held within the screw head cavity, andwherein the adjustment screw can be threaded through the screwengagement feature of the mounting base, so that that turning theadjustment screw in a first direction will cause the mounting clip toslide relative to the mounting base to increase the combined height ofthe mounting clip and the mounting base, and wherein turning theadjustment screw in a second direction will cause the mounting clip toslide relative to the mounting base to decrease the combined height ofthe mounting clip and the mounting base. The at least one mounting clipcan include at least one solar module frame engagement feature that isconstructed and arranged to be attached to a solar module. The systemcan include at least one non-conductive frame that includes a lowerframe engagement feature and an upper frame engagement feature. Thelower engagement feature can be configured to engage with the at leastone mounting clip, and the upper engagement feature can be configured tobe attached to a solar laminate. The mounting clip can include aflexible member configured to flex under force. The mounting clip can beconfigured to have a solar module attached to the at least one mountingclip. At least one of the mounting base, the mounting post, the mountingclip, and a PV module frame are comprised of a non-electricallyconductive material, so that the system is free of a grounding unit. Theat least one mounting clip can include a fast-release mechanismconfigured to release the solar module when a vector force is applied tothe fast release mechanism. The mounting clip can include an adhesiveconfigured to secure a solar module to the mounting clip. The adhesivecan be a reclosable fastener system.

A method for installing a solar module can include engaging a mountingbase into a snap-in groove of an adjustable foot, sliding the mountingbase within the snap-in groove of the adjustable foot to position themounting base in a desired location along the adjustable foot, pressingthe mounting base into the adjustable foot, so that the mounting basedisengages from the snap-in groove and so that a mounting baseengagement feature is pressed into engagement with a foot engagementfeature, thereby securing the mounting base to the adjustable foot,turning an adjustment screw that connects a mounting post to themounting base, so that the height of the mounting post is adjustablerelative to the adjustable foot, and attaching a solar module to amounting clip attached to the mounting post. The method can includeinstalling a flashing with a clearing hole at least partially under ashingle on a roof, aligning a bolt hold in the adjustable foot with theclearing hole, and installing a bolt through the bolt hold in theadjustable foot, through the clearing hole, and into the roof. Attachingthe solar module to the mounting clip can include attaching a solarlaminate to a frame, and attaching the frame to the mounting clip. Themethod can include releasing the solar module from attachment to themounting clip by applying a vector force to a fast-release mechanism onthe mounting clip or adjustable foot.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention description below refers to the accompanying drawings, ofwhich:

FIG. 1 is a perspective view of a system for mounting PV modules to arooftop, according to an illustrative embodiment;

FIG. 2 is an exploded perspective view of the mounting system of FIG. 1,according to an illustrative embodiment;

FIG. 3 is an exposed side view of the mounting system of FIG. 1, showingthe inner workings of a north-south foot and its interaction with amounting base, according to an illustrative embodiment;

FIG. 4 is a perspective view of a system with wings and an exterior snapfitting for mounting PV modules to a rooftop, according to anillustrative embodiment;

FIG. 5A is an end view of the system of FIG. 4 with wings and exteriorsnap fitting for mounting PV modules to a rooftop, according to theillustrative embodiment;

FIG. 5B is an enlarged partial end view of the snap fitting and snap-inchannels of FIG. 5A, showing the snap-fitting engaged in the firstsnap-in channel, according to the illustrative embodiment;

FIG. 5C is an enlarged partial end view of the snap fitting and snap-inchannels of FIG. 5A showing the snap-fitting engaged in the secondsnap-in channel, according to the illustrative embodiment;

FIG. 6A is an exposed side view of the mounting system of FIG. 1 shownat a first vertical adjustment height, according to an illustrativeembodiment;

FIG. 6B is an exposed side view of the mounting system of FIG. 6A shownat a second vertical adjustment height, according to an illustrativeembodiment;

FIG. 7 is a side view of a PV module mounting system showing clipsattached to the mounting system by pins, according to an illustrativeembodiment;

FIG. 8A is a side view of a PV module frame engaged with a top clip,according to an illustrative embodiment;

FIG. 8B is a side view of a PV module frame engaged with a bottom clip,according to an illustrative embodiment;

FIG. 9A is a side view of an alternate PV module frame engaged with atop clip, according to an illustrative embodiment;

FIG. 9B is a side view of the alternate PV module frame engaged with abottom clip, according to an illustrative embodiment;

FIG. 10A is a side view of a PV module frame adhered to a top clip,according to an illustrative embodiment;

FIG. 10B is a side view of a PV module frame adhered to a bottom clip,according to an illustrative embodiment;

FIG. 11A is a side view of a PV module frame engaged with a top clip,according to another illustrative embodiment;

FIG. 11B is a side view of a PV module frame engaged with a bottom clip,according to another illustrative embodiment;

FIG. 12A is a perspective view of a flashing with raised guides,according to an illustrative embodiment;

FIG. 12B is a bottom view of a foot with a mating profile and a footbase, according to an illustrative embodiment;

FIG. 13 is a cross sectional view of a flashing, a foot, and awaterproof union, taken along cross section line 13-13 of FIG. 5A,according to an illustrative embodiment;

FIG. 14 is a cross sectional view of a flashing with a plateau, a foot,and a waterproof union, taken along cross section line 13-13 of FIG. 5A,according to an illustrative embodiment;

FIG. 15 is a cross sectional view of a flashing with a trench, a foot,and a waterproof union, taken along cross section line 13-13 of FIG. 5A,according to an illustrative embodiment;

FIG. 16 is a cross sectional view of a flashing, a foot, and awaterproof union with an elastomeric seal, taken along cross sectionline 13-13 of FIG. 5A, according to an illustrative embodiment;

FIG. 17 is a cross sectional view of a flashing with an open feature toallow trapped water to escape, a foot, and a waterproof union with anelastomeric seal, taken along cross section line 13-13 of FIG. 5A,according to an illustrative embodiment;

FIG. 18 is a cross sectional view of a flashing, a foot, and awaterproof union with additional elastomeric seals, taken along crosssection line 13-13 of FIG. 5A, according to an illustrative embodiment;

FIG. 19A is a bottom view of an exemplary rail-less mounting system witha displacement restrictor, according to an illustrative embodiment;

FIG. 19B is a perspective view of the exemplary rail-less mountingsystem of FIG. 19A with a displacement restrictor, according to theillustrative embodiment;

FIG. 20A is a perspective view of a building and sloped rooftop withstandard fire setbacks, according to the prior art; and

FIG. 20B is a perspective view of an exemplary building and slopedrooftop with reduced fire setbacks, according to an illustrativeembodiment.

DETAILED DESCRIPTION

The present disclosure is an illustrative example of a roof mountingsystem for PV modules that achieves the stated benefits. This should beviewed as an illustrative embodiment of the invention, intended toexplain the features and as will be appreciated by those skilled in theart by no means the only way to achieve the stated utility of theinvention.

FIG. 1 is a perspective view of a system for mounting PV modules to arooftop, according to an illustrative embodiment. In the embodiment, aPV mounting system 100 can include a flashing 102, waterproof union 104,adjustable foot 106, mounting stand 108, a top clip 110, and a bottomclip 112. The system can be installed with direction arrow 118 pointingto the top of the roof. Bottom clip 112 can hold the bottom of an upperPV module that is mounted closer to the top of the roof, and top clip110 can hold the top of a lower PV module that is mounted farther fromthe top of the roof. Mounting stand 108 can have a mounting base 114 anda mounting post 116. Foot 106 can have a floor 120, sidewalls 122, and astopper 124.

This type of a system can allow for mounting clips 110 and 112 to beadjusted into place to accommodate the solar cells that can be part ofan assembled PV module after the system is secured to the roof. Thesystem allows for the location of the PV modules to be adjusted in threeaxes. The system can be adjusted along the y-axis (up and down slope ofthe roof), shown as parallel to direction 118, by sliding mounting base114 inside the up-down adjustable foot 106 until the mounting base 114is in a desired location that can align properly with a PV module frame.The PV module frame can further slide within the top clip 110 and/orbottom clip 112 in a back-and-forth direction along the x-axis, or putanother way, across the slope of the roof in a direction perpendicularto arrow 118, allowing for adjustment of the entire array of one or morePV modules from side to side. When the system is fine tuned in the planeof the roof, modules can be secured to top clip 110 by forcing themodule's frame into top clip 110 and snapping the fitting into place,explained more fully below. This snap fit method of mechanical securingis well known to those skilled in the art. The clips shown in FIG. 1 areexemplary, and various clip embodiments can be used, as explained morefully below. Mounting base 114 can be secured to north-south adjustablefoot 106 by snapping the mounting base 114 into place in the adjustablefoot 106. Mounting post 116 can be adjustable by means of a levelingscrewing mechanism to allow for vertical adjustment of the PV modulealong the z-axis in the direction perpendicular to the plane of the roof

FIG. 2 is an exploded perspective view of the mounting system of FIG. 1,according to an illustrative embodiment. An exemplary method forsecuring flashing 102 and north-south foot 106 to a roof is explainedbelow. Flashing 102 can be a sheet of material that can be, for example,a metal or rigid plastic material. Flashing 102 can have an insertionedge 202 that can be slid under sloped roof coverings such as, forexample, ubiquitous composite shingles, so that at least a portion ofthe flashing 102 can be under the roof covering, and water can flow overthe roof covering in the case of rain. Flashing 102 can be made from anydurable, waterproof material that is approved for use on a roof by ULand other approval agencies. These materials include but are not limitedto aluminum, steel, copper, some plastics and composite materials.Flashing 102 can be formed such that a there is a sufficient clearinghole 204 for a fastener, such as a lagging bolt 206, to be placed thoughthe flashing 102 in order to secure the system to the roof. A raisedneck rim 208 on flashing 102 can also be raised with respect to the restof flashing 102 to ensure that any water running down the roof cannotflow into clearing hole 204. Adjustable foot 106 can have a matingprofile 210 that can mate with neck rim 208 so that mating profile 210and neck rim 208 can fit together snugly. In various embodiments, themating profile 210 can be inserted into and engaged within the neck rim208. An outer surface of the mating profile 210 can seal against aninner surface of the neck rim 208 to prevent water from entering theclearing hole 204, explained more fully below. Adjustable foot 206 canhave a fastener hole 212 with a seat 214 for a lagging bolt 206 or otherfastener. Fastener hole 212 can allow lagging bolt 206 to pass throughthe foot 106, into the roof via clearing hole 204 in flashing 102. Aslagging bolt 206 is screwed into the roof, it can engage the matingsurfaces of seat 214, force adjustable foot 106 onto flashing 102, andforcing mating profile 210 to mate with neck rim 208. When matingprofile 210 is engaged with neck rim 208, they can form the waterproofunion 104. Lagging bolt 206 or seat 214 can incorporate a waterproofingcompressible seal, such as a gasket or o-ring, so that engagement of thebolt 206 with the seat 214 can provide a watertight seal, and preventwater from entering the fastener hole 212. These types of seals areubiquitous and available commercially off-the-shelf from a number ofsuppliers. As will be appreciated by those skilled in the art, forcingmating profile 210 into engagement with neck rim 208 can further securethe interface between the neck rim 208 of the flashing 102 andadjustable foot 106 to prevent any water from flowing from the surfaceof flashing 102 into clearing hole 204 and thus into the roof

Flashing 102 can also be optionally equipped with horizontal alignmentnotches 216 that can be used to align flashing 102 with mountingmarkings on the roof. Similarly, vertical alignment notch 218 can allowfor alignment with fiduciary marks that can be made along the rafter onthe roof to assure that lagging bolt 206 is secured into the rafter ofthe roof. Optionally insertion edges 202, and particularly a leadingcorner 220, can be beveled so that the act of sliding flashing 102 underroof shingles does not damage said shingles.

FIG. 3 is an exposed side view of the mounting system of FIG. 1, showingthe inner workings of an adjustable foot and its interaction with amounting base, according to an illustrative embodiment. Adjustable foot106 can be equipped with foot snap-in grooves 302 that can engage withcorresponding base snap-in grooves 304 on the mounting stand 108. Thesegrooves 302 and 304, once engaged with each other, can prevent base 114from sliding up the roof in the direction of arrow 118, or down the roofin a direction opposite to arrow 118. The mounting base 114 can beengaged in a first engagement position with the foot 106, and in thefirst engagement position the mounting base 114 can slide along thelength of the foot 106. The mounting base 114 can be further engagedinto a second engagement position with the foot 106, so that the footsnap-in grooves 302 and the base snap-in grooves 304 are enmeshedtogether, so that the mounting base 114 can be held in a fixed locationrelative to the foot 106. In various embodiments, the mounting base 114can be quickly disengaged from the foot 106 and easily repositioned, ifnecessary, explained more fully below.

In an embodiment, the foot 106 can have a snap-fitting 306 that canextend at least partially along the length of the foot 106, and themounting stand 108 can have a first clip-in channel 308 and a secondclip-in channel 310 on the mounting base 114. In various embodiments,snap-fitting 306 can be one or more inward ridges that can extendinwards from the sidewalls 122, or other protrusions extending inward.As shown in FIG. 3, snap-fitting 306 can be a series of inwardprotrusions extending inward from a portion of the sidewall 122 near thetop of the sidewall 122. The first clip-in channel 308 on the mountingbase 114 allows for the mounting base 114 to be engaged withsnap-fitting 306 on north-south foot 106, with the snap-in base grooves304 held above the snap-in foot grooves 302, without the snap-in basegrooves 304 being engaged with the foot grooves 302, thus allowing themounting base 114 to slide freely within north-south foot 106. Once theinstaller determines the correct position of mounting base 114 withrespect to north south foot 106, the snap fitting 306 can be disengagedfrom the first clip-in channel 308 and the mounting base can be pusheddown to engage a second snap-in channel 310 with the snap fitting 306,so that snap-in base grooves 302 and foot grooves 304 are intermeshedtogether, thereby securing the base 114 to the foot 106 together, andthus negating any free movement of mounting base 114 with respect tonorth-south foot 106.

FIG. 4 is a perspective view of a system with wings and an exterior snapfitting for mounting PV modules to a rooftop, according to anillustrative embodiment. In the embodiment, a PV mounting system 400 caninclude a flashing 102, waterproofing union 104, adjustable foot 406,mounting stand 408, and top and bottom clips 410 that can be the same ormirror images. Having the same clip 410 for the top and bottom clip canreduce the number of parts required for an installation, which canreduce the time and cost of the installation. The system can beinstalled with direction arrow 118 pointing to the top of the roof.Mounting stand 408 can have a mounting base 414, a mounting post 416,and at least one wing 418. Foot 406 can have a floor 420, sidewalls 422,and a stopper 424. The at least one wing 418 can extend outward from themounting stand 408 and downwards over at least a portion of the sidewall422.

The foot 406 can have a snap fitting 426 that can extend at leastpartially along the length of the foot, and the mounting base 408 canhave a first clip-in channel and a second clip in channel on an innersurface of the wing 418, explained more fully below. In variousembodiments, snap fitting 426 can be one or more outward ridges that canextend outwards from the sidewalls 422, or other protrusions extendingoutward. As shown in FIG. 4, snap fitting 426 can be a ridge extendingoutwards from a portion of the sidewall 422 near the top of the sidewall422. Adjustable foot 406 can have foot snap-in grooves 302, and themounting stand 408 can have base snap-in grooves, so that foot snap-ingrooves 302 and base snap-in grooves can engage with each other, asshown in FIG. 3 and described above, to prevent mounting stand 408 fromsliding within the foot 406.

FIG. 5A is an end view of the system of FIG. 4 with wings and exteriorsnap fitting for mounting PV modules to a rooftop, according to theillustrative embodiment. As shown in FIG. 5, the PV mounting system 400can have clips 410, a mounting stand 408, a foot 406, waterproof union104, and flashing 112. The mounting stand 408 can have wings 418 with afirst clip-in channel 502 and a second clip-in channel 504. The foot 406can have sidewalls 422 with snap fittings 426. An installer can engagethe mounting stand 408 with the foot 406 by pressing the mounting stand408 onto the foot 406 so that the wings 418 flex outwards and/or thesidewalls 422 flex inwards until the snap-fitting 426 snaps into placein the first snap-in channel 502. With the snap fitting 426 engaged inthe first snap-in channel 502, the mounting stand 408 can be maintainedin a first engagement position with the foot 406, and can slide alongthe length of the foot 406.

FIG. 5B is an enlarged partial end view of the snap fitting and snap-inchannels of FIG. 5A, showing the snap fitting engaged in the firstsnap-in channel, according to the illustrative embodiment. When themounting stand 408 is in the first engagement position, the snap-fitting426 can be engaged in the first snap-in channel 502, and the secondsnap-in channel 504 can be empty. With the mounting stand 408 in thefirst engagement position, the mounting stand 408 can be adjusted into adesired location, and then the mounting stand 408 can then be furtherpressed onto the foot 406 so that the snap-fitting 426 can snap into thesecond snap-in channel 504. FIG. 5C is an enlarged partial end view ofthe snap fitting and snap-in channels of FIG. 5A, showing the snapfitting engaged in the second snap-in channel, according to theillustrative embodiment. When the mounting stand 408 is in the secondengagement position, the snap-fitting 426 can be engaged in the secondsnap-in channel 504, and the first snap-in channel 502 can be empty.

Turning back to FIG. 5A, when the snap fitting 426 is engaged in thesecond snap-in channel 504, the mounting stand 408 can be in a secondengagement position with the foot 406. In the second engagementposition, the foot snap-in grooves 302 and the base snap-in grooves 304can be enmeshed together so that the mounting stand 408 can be held in afixed location relative to the foot 406. It is specifically contemplatedthat in various embodiments, there can be more than one snap fitting 426and more than two snap-in channels, so that the first and secondengagement positions can be each held by a plurality of snap-fittingsengaged in channels on each side.

In various embodiments of PV module installation the mounting stand 408can first be pressed into the first engagement position, and then a PVmodule frame can be attached to a clip 410 prior to pressing themounting stand 408 into the second engagement position. An installer candetermine the desired location for the PV module and the PV moduleframe, and therefore the correct location for the mounting stand 408,while the mounting stand 408 is still in the adjustable first engagementposition and can then press the mounting stand downwards into the secondengagement position in the desired location.

The mounting stand 408 can be quickly and easily removed from the foot406 for further adjustments, emergencies, or repairs. An installer orother user can remove the mounting stand 408 from the foot 406 by firstpressing inwards on the sidewalls 422 along vector arrows 510. When thesidewalls 422 are pressed inwards along vector arrows 510, thesnap-fittings 426 can be disengaged from the snap-in channels, therebyfreeing the mounting stand 408 from the foot 406 so that the mountingstand 408 can be removed.

An example of a mechanism to enable post-installation verticaladjustment is shown in FIGS. 6A and 6B. FIG. 6A is an exposed side viewof the mounting system of FIG. 1 shown at a first vertical adjustmentheight, and FIG. 6B is an exposed side view of the mounting system shownat a second vertical adjustment height, according to an illustrativeembodiment. The height of mounting stand 108 can be adjusted by slidingmounting post 116 within mounting base 114. An adjusting screw 602 canbe seated in a cavity 604 so that the top and bottom of its head is incontact with a section of mounting post 116, thereby securing thelocation of the adjusting screw 602 relative to the mounting post 116.Adjusting screw 602 can engage a threaded feature 606, such as a barnut, that can be secured in mounting base 114. Thus, by turningadjusting screw 602 clockwise, the adjusting screw 602 is lowered in thethreaded feature 606 and pulls mounting post 116 down. Conversely whenadjusting screw is tuned counter-clockwise, it is displaced upwards inthreaded feature 606, and thus pushes mounting post 116 upward. Asanyone skilled in the art will appreciate, clockwise andcounter-clockwise for up and down can be interchanged easily and suchmechanisms are ubiquitous and illustrated here merely per example.Adjustment of the height of the mounting stand 108 is dependent on thelength of adjusting screw 602 as well as the length of mounting post 116and mounting base 114. FIG. 6A shows the system in its lowest positionand FIG. 6B shows the system fully extended. Adjustment can be in arange from approximately 0.5 inches to approximately 6 inches dependingon the design variables above. Mounting post 116, mounting base 114,threaded feature 606, and adjusting screw 602 can be made from variousmaterials such as metals that will include steel, stainless steel,aluminum and various plastics that are suitable to forming such asthermoplastics and thermosets, filled and unfilled. The filler can beglass, carbon fiber or any other material known in the art to providepositive benefits to mechanical and physical properties. The choice ofmaterial for any of these components should be selected so that theypass the relevant UL or international standards such as UL2703. IEC61215 and IEC 61730.

In order to rotate adjusting screw 602, a tool that engages a receptacleor head in adjustment screw 602 can be utilized. Such a tool can bemechanized or not and can provide additional torque and speed ofrotating to speed up installation. The system can also be made such thattool gap 608 is large enough to enable the seamless inserting andremoving of a tool to engage adjusting screw 602. As another example,the tool that is utilized to rotate adjusting screw 602 can be the sameas the one utilized to rotate lag bolt 206. This drives installationcost down by reducing the number of tools required for systeminstallation to one, further reducing number of parts and the number oftools to be taken onto the roof as well as speeding up the installationand saving direct labor time.

In some applications, the height adjustment or leveling function may notbe required. Accordingly, in various embodiments the number of parts canbe further reduced by using a mounting stand that does not have theheight adjustment feature. A mounting stand without the heightadjustment feature can be a fixed-height mounting stand and can be freeof the separate mounting base and mounting post. A fixed-height mountingstand can retain the base snap-in grooves, the snap-in channels, themounting holes for clips and/or other features. The fixed-heightmounting stand can be smaller, lighter, and/or less expensive tomanufacture than an adjustable-height mounting stand with the separatemounting base and mounting post that provide the height adjustment orleveling function. The adjustable-height mounting stand can be anoptional feature.

FIG. 7 is a side view of a PV module mounting system showing clipsattached to the mounting system by pins, according to an illustrativeembodiment. Clips 702 can have a mounting interface area 704 near thebottom of the clip 702, and the mounting interface area 704 can be usedto mount the clips 702 to the mounting stand 408. Mounting stand 408 canhave a plurality of mounting holes near the top of the mounting stand,and clips 702 can each have at least one mounting hole or mounting notchin the mounting interface 704. Clips 702 can be attached to the mountingstand 408 by passing fasteners such as pins 706 through the mountingholes or mounting notches in the mounting interface 704 and through themounting stand 408. Pins 704 can be a rolled stainless steel spring pin,or a solid pins of stainless steel, bolts with nuts, cotter pins, orother pins produced from various materials that can provide appropriatestrength without loosening or displacing over time.

A wide variety of clips can be utilized in the PV module mountingsystem, and can accommodate a wide variety of PV module frames. Invarious embodiments, the PV module mounting system can be manufacturedand sold with different clips attached to the mounting stand 408 withpins 706. The choice of clip can depend on the needs of individualinstallation jobs based on the particular PV module frame to beinstalled, explained more fully below. In alternate embodiments, themounting stands 408 and clips can be sold separately, and an installeror other user can assemble each mounting stand to have an appropriateclip depending on the needs of individual installation jobs.

FIGS. 8A and 8B show an illustrative example of how a PV mounting systemcan be attached to a conventional PV module with a standard aluminum PVframe. FIG. 8A is a side view of a standard PV module frame engaged witha top clip, FIG. 8B is a side view of a standard PV module frame engagedwith a bottom clip, according to an illustrative embodiment. A typicalmodule frame profile, 802, is an extruded aluminum beam that hasmounting cavity 804 and attachment lip 806. Mounting cavity 804 isdesigned to receive the solar laminate, including at least one solarcell, and the laminate can be affixed to frame 802. The laminate can beaffixed to the frame 802 with an adhesive, or other means as will beappreciated by those skilled in the art.

In various embodiments, top clip 810 and bottom clip 812 can be mirrorimages of each other, as shown in FIGS. 8A and 8B. Top clip 810 andbottom clip 812 can each have a mounting interface 814. Mountinginterface 814 can have at least one hole for a mounting pin, and canconnect mounting clips 810 and 812 to the mounting post 116 as shown inFIG. 1 via at least one pin as will be appreciated by those skilled inthe art. Both clips can have a receptacle lip 816 formed so thatattachment lip 806 of frame 802 can slide and nest within it. Receptaclelip 816 is further designed and formed to allow for the misalignment offrames 802, the thermal expansion of frame 802, as well as to withstandthe forces imposed on it by wind and snow loads. Because the frame isnot rigidly clamped by the clip, the frame can be out of square orotherwise not at right angles and the clip can continue to retain theframe. The frame can also slide in the clip in both the directions ofthe x and y axes as the module grows or contracts under heat and/orcold. Mounting clips 810 and 812 can be made from a number of plasticsand metals as appreciated by those skilled in the art. Mounting clips810 and 812 can be formed by means of extrusion, molding includinginjection molding, machining or any other method that allows thematerial to be formed so that it performs the intended function. As canbe appreciated by those skilled in the art, the example in FIGS. 8A and8B is purely illustrative, and top and bottom mounting clips can takeany form and be made from any material as long as it performs thefunction of securing frame 802 to keep it in place under all operatingconditions as well as pass all required certification tests.

FIG. 9A is a side view of an alternate PV module frame engaged with atop clip, and FIG. 9B is a side view of the alternate PV module frameengaged with a bottom clip, according to an illustrative embodiment.Mounting clips 920 and 922 can be secured to post 116 via pins throughholes in mounting interface 814. In this example, a frame 902 of a PVmodule is shown with an alternate form with unique features. As will beappreciated by those skilled in the art these features can take on amultitude of shapes and forms in order to accomplish the functionsrequired of the frame. The functions of the frame can include containingthe solar laminate of a PV module, attaching the module to the mountinghardware and providing structural strength to the PV module. In theillustrative example of FIG. 9A and 9B, frame 902 can include a laminatemounting cavity 904, a mounting securing face 906 and a top clipinterface As will be apparent the laminate can be supported by mountingcavity 904 and mounting securing face 906, and can be secured with anadhesive or other means of securing the frame to the clip, as will beapparent to one skilled in the art. The structure and cross section offrame 902 can be determined by the normal and shear forces that act onthe frame during required operations. There are a number of ways tooptimize the shape and size of the frame depending on the material used,the expected operating conditions and code requirements.

The frame can also feature mounting lip 910 and slip face 912. Themounting lip 910 and the slip face 912 can interact with top clip 920and bottom clip 922 as shown, after the PV module is assembled. Bottomclip 922 can have a securing arm 924 that can mate with mounting lip910, thereby securing frame 902 to bottom clip 922 while bottom clip 922supports the frame 902. Top clip 920 can have a wall 926 and a springmember 928 with cavity 930. To secure frame 902, frame 902 can be pusheddown onto spring member 928, thereby pushing cavity 930 away from wall926, creating enough space for mounting lip 910 to slide into cavity930. The combination of shape and material of spring member 928 can besuch that it acts like a spring, so that it can allow cavity 930 to moveaway from wall 926, while still applying a resisting force toward wall926. This proportional force can secure lip 910 into cavity 930 and pushslip face 912 onto wall 926, so that the frame 902 can be held in placebetween the cavity 930 and the wall 926. It should be clear to thoseskilled in the art that the mechanisms described above can allow frame902 to be secured to clips 920 and 922, and that the act of attachmentwill provide feedback that the system is secured. This feedback might bein the form of tactile, audio or visual means. The design describedabove contains certain features to accomplish the goal of mounting frame902 to clips 920 and 922. It will be obvious to those skilled in the artthat these features serve as an example and can be obtained by differentmeans and designs. It should also be obvious that the features of clips920 and 922 are adapted to hold the frame 902, and that in variousembodiments various clips can be used to hold various frames.

When frame 902 of a PV module is secured to the roof via clips 920 and922 of the mounting system it will be subjected to a number ofmechanical loading conditions. These include snow loads, wind loads,gravitational loads, and loads due to installers walking onto the PVmodules. It is an object of this invention to provide a mounting systemthat will be able to withstand all these required loads and keep frame902 secured during these loading conditions. During loading conditions,clips 920 and 922 can be flexible to avoid breaking, and can increasetheir holding strength of the frame 902 and the securing of the frame902 when clips 920 and 922 are flexed. In the case of snow loading, themodule can experience a downward force that can in turn cause bottomclip 922 to rotate clockwise as shown by direction arrow 932, and topclip 920 to rotate counter-clockwise as shown by direction arrow 934.Bottom clip 922 and top clip 920 can flex to allow rotation. Under thisrotational force, frame 902 in clip 920 can force lip 910 into cavity930, thereby bending and displacing spring member 928, furtherincreasing the downward force on lip 910 and increasing the force of theengagement between clip 920 and frame 902. Similarly, as frame 902rotates clockwise on bottom clip 922 mounting lip 924 will resist thedisengagement of lip 910. Both clips 920 and 922 are designed withspring arm 936 that will resist these motions less than a stiff clipwould. This is intended to reduce the stress concentrations on the clipmaterial, thereby enabling the use of softer materials such as plasticsor engineered composites without the fear of stressing the materialbeyond the point of failure. Similarly when wind load is applied to PVmodule, it can place an upward force on frame 902, rotating frame 902 inbottom clip 922 counter-clockwise and frame 902 in top clip 920clockwise, in the opposite direction from arrow 934. In this case, slipface 912 can be forced into wall 926, reducing the probability of frame902 rotating out of top clip 920. The upward force on frame 902 can alsoengage lip 910 into the cavity 930 of the top clip 920 and mounting lip924 of the bottom clip 922, further decreasing the possibility of thesystem releasing frame 902.

A PV mounting system can have a fast-release feature, so that panels canbe removed quickly for emergencies, for repair, for readjustment, orother reasons. In various embodiments, when it is required to releaseframe 902 from the mounting system, pulling spring member 928 back alongvector arrow 938 away from frame 902 can release lip 910 from cavity930, thereby allowing for frame 902 of the PV module to be released fromtop clip 920. Once frame 902 is released from top clip 920, frame 902can be rotated to such an angle that lip 910 can rotate out of securingarm 924 thereby releasing frame 902 completely from the mounting system.In various embodiments, spring member 928 can be broken off utilizing atool such a crow bar, thereby releasing the frame 902 from top clip 920.The top clip containing the broken spring member 928 can be replacedafter maintenance or emergency services are complete by removing the pinfrom the mounting interface and replacing the top clip, or replacing themounting post, or replacing the entire mounting stand. As describedabove in regard to FIG. 8, the mounting base of the mounting stand canalso be quickly removed from the foot, allowing for easy adjustment,repair, and/or replacement.

In various embodiments of a PV mounting system, frame 802, 902 or otherframes utilized in a PV module can be adhered to the mounting systemwith an adhesive. FIG. 10A is a side view of a PV module frame adheredto a top clip, and FIG. 10B is a side view of a PV module frame adheredto a bottom clip, according to an illustrative embodiment. Top clip 1002and bottom clip 1004 can have an extended flat lip 1006 with an adhesionsurface 1008. In the illustrative example shown in FIGS. 10A and 10B,conventional frame 802 is used but it should be clear that theprinciples disclosed herein using adhesive can work with any type offrame profile. Adhesive 1010 can be placed between frame 802 and theadhesion surfaces 1008 of clips 1002 and 1004. The adhesive 1010 canbond clips 1002 and 1004 to frame 802. To withstand the required forcesplaced onto adhesive 1010, the length of clips 1002 and 1004 into thepage, along the y-axis in a side-to-side direction along the roof, issized such that sufficient surface area of adhesive 1010 is in contactwith both clips 1002 and 1004, and frame 802. The manufacturer ofadhesive 1010 issues a product specification that stipulates the arearequired for a specified force, and this can be utilized to calculatethe minimum contact area between top clip 1002 and frame 802, andbetween bottom clip 1004 and frame 802. As will be understood by thoseskilled in the art, adhesive 1010 can be of any type of adhesive. Forexample adhesive 1010 can be a glue, an epoxy that is made up of one ormore parts, a peel and stick type tape such as 3M VHB or any other typeof adhesive. Furthermore, adhesive 1010 can be of a quick release typeor reclosable type such as a hook-and-loop (e.g. Velcro®) system or aDual-Lock™ system that can withstand the required loads but can bereleased when subjected to other types of loads. Furthermore, thematerials utilized for the adhesives can take on a number of metals,non-metals and plastics, as long as they fulfill the relevantcertification requirements. Additionally adhesive 1010 can be placed ona surface that can be flat as shown in FIGS. 10A and 10B, or on anon-flat surface that mates clips 1002 and 1004 to frame 802.

FIG. 11A is a side view of a PV module frame engaged with a top clip,and FIG. 11B is a side view of a PV module frame engaged with a bottomclip, according to another illustrative embodiment. Top clip 702 andbottom clip 702 can be the same or mirror images of each other. Clips702 can have a mounting area 704, a lower spring section 1102, a flatsurface 1104, a bulwark 1106, and a holding arm 1108 that can have oneor more holding fingers 1110. A frame 802 can be supported on flatsurface 1104 and can rest against bulwark 1106. The holding arm 1108 cancurl up and around and onto the lower portion of the frame and can holdthe frame 802 in place. The arm 1108 can have a spring quality, so thatwhen forces are exerted on the frame that can pull or push the frame outof engagement with the clip 702, those forces can load the spring of thearm 1108, thereby increasing the force the arm exerts downward on thelower portion of the frame to retain the frame in place. The lowerspring section 1102 can also flex up or down as needed in response toforces exerted on the PV module. In various embodiments, an adhesive canbe used to secure the frame 802 to the flat surface 1104.

The various examples above should illustrate to those skilled in the artthat a multitude of frames and clips can be utilized in unison to ensurethat the frame is secured to the mounting system under all loadingconditions and furthermore provide for fast installation and ease ofrelease. It should be noted that the clips can be custom designed forspecific frames in order to achieve the improvements of the mountingsystem as described. Furthermore, as will be known to those skilled inthe art, utilizing pins and mounting holes in mounting interface 814 toattach top and bottom clips to top post 116 will enable the mountingsystem to be used with any frame and clip combination.

FIG. 12A is a perspective view of a flashing with raised guides,according to an illustrative embodiment. A flashing 102 can have aclearing hole 204, a raised neck rim 208, and at least one raised guide1202. The at least one raised guide 1202 can be used to help guide afoot into the desired position on the flashing 102. FIG. 12B is a bottomview of a foot with a mating profile and a foot base, according to anillustrative embodiment. A foot 106 can have a fastener hole 212, amating profile 210, and a raised foot base 1212. Foot base 1212 can haveguide areas 1214 that can be used to help guide the foot 106 intoposition on the flashing 102. An installer can set the foot 106 inapproximately the right location on the flashing, and the raised guide1202 and the foot base 1212 can provide tactile feedback to theinstaller when the foot base 1212 has shifted down into the desiredposition with the guides 1202 in the guide areas 1214.

FIG. 13 is a cross sectional view of the foot, flashing, and waterproofunion, taken along cross section line 13-13 of FIG. 5A, according to anillustrative embodiment. Foot 106 can have a floor 120 with foot grooves302, a foot base 1212, a fastener hole 212, a seat 214, an elastomericseal 1302, and a mating profile 210. Flashing 102 can have at least oneraised guide 1202 and a neck rim 208. The waterproof union 104 can beformed when the foot 106 is engaged with the flashing 102. Thewaterproof union 104 can provide multiple barriers to the ingress ofwater below the flashing. The foot base 1212 can provide a first barrierto water ingress by diverting the flow of water down the flashing whenthe system is positioned in a typical configuration on a sloped roof.The foot base 1212 can be separated substantially from the neck rim 208,and the raised neck rim 208 can act as a second barrier to any waterthat is not diverted away by the foot base 1212. A third barrier towater ingress can be formed when the mating profile 210 forms aninterference fit with the inside of the hole of the neck rim 208. Themating profile 208 can have a cork section 1304 that can be aconstant-diameter cylinder, and a curved or sloped transition section1306 below the cork section 1304. The transition section 1306 can beinserted into the neck rim 208, and then when the bolt 206 is tightenedinto the roof the cylindrical cork section 1304 can be drawn down intothe neck rim 208 to form a watertight seal between the neck rim 208 andthe mating profile 210. In various embodiments, the cylindrical corksection 1304 of the mating profile 210 can increase slightly in diameterfrom bottom to top to improve the interference fit with the neck rim208. Mating profile 210 can fit tightly inside the neck rim 208 without(free of) contacting the upper surface of the flashing 102 or the uppersurface of the neck rim 208. Neck rim 208 can fit tightly around themating profile 210 without (free of) contacting the lower surface of thefoot 106. In various embodiments, the flashing 102 and neck rim 208 canbe made of a metal and the foot 106 and mating profile 210 can be madeof a plastic, so the plastic mating profile 210 can deform slightly asit is drawn into the neck rim 208, thereby allowing the plastic matingprofile 210 to conform to the neck rim 208, and increasing theeffectiveness of the seal.

FIG. 14 is a cross sectional view of a flashing with a plateau, a foot,and a waterproof union, taken along cross section line 13-13 of FIG. 5A,according to an illustrative embodiment. In various embodiments, aflashing 102 can have a raised plateau 1402. The raised plateau 1402 andthe foot base 1212 can be sized and shaped to nestle together, therebyforming an additional barrier to the ingress of water. The raisedplateau 1402 can include a plateau wall 1404 and lower plateau corner1406, and the foot base 1212 can be pulled tight against the plateauwall 1404 and plateau corner 1406 when the fastener 206 is tightenedinto the roof.

FIG. 15 is a cross sectional view of a flashing with a trench, a foot,and a waterproof union, taken along cross section line 13-13 of FIG. 5A,according to an illustrative embodiment. In various embodiments, aflashing 102 can have a trench 1502. The trench 1502 and foot base 1212can be sized and shaped to nestle together to help to locate the foot onthe flashing, and thereby forming an additional barrier to the ingressof water. The foot base 1212 can be pulled tight into the trench 1502when the fastener 206 is tightened into the roof

FIG. 16 is a cross sectional view of a flashing, a foot, and awaterproof union with an elastomeric seal, taken along cross sectionline 13-13 of FIG. 5A, according to an illustrative embodiment. In anembodiment, the waterproof union 104 can include an elastomeric seal1602 between the foot 106 and the flashing 102. Elastomeric seal 1602can be EPDM or other elastomeric materials as will be understood by oneskilled in the art. The elastomeric seal 1602 can be used in conjunctionwith a trench 1502, as shown in FIG. 16, however, it should be clearthat the elastomeric seal can be also used in any of the aboveembodiments, including a plateau or a flush surface of a flashing 102.When the fastener 206 is tightened into the roof, the foot 106 can bepulled down towards the flashing 102, and the elastomeric seal 1602 canbe compressed between the foot base 1212 and the flashing 102.

FIG. 17 is a cross sectional view of a flashing with an open feature toallow trapped water to escape, a foot, and a waterproof union with anelastomeric seal, taken along cross section line 13-13 of FIG. 5A,according to an illustrative embodiment. The flashing 102 can have anopen groove 1702 at a downhill portion of the waterproof union 104. Theopen groove 1702 can be in a small area under the portion of the footbase 1212 that is farthest from the top of the roof, so that anymoisture that may be within the foot base 1212 can escape and run downthe roof

FIG. 18 is a cross sectional view of a flashing, a foot, and awaterproof union with additional elastomeric seals, taken along crosssection line 13-13 of FIG. 5A, according to an illustrative embodiment.In various embodiments, a waterproof union can have one or moreelastomeric seals. Elastomeric seal 1602 can be between the foot base1212 and the flashing 102. Elastomeric seal 1802 can be located abovethe neck rim 208 and under the foot 106, so that when the foot 106 ispulled onto the flashing 102, the neck rim 208 can either press into theelastomeric seal 1802, or can be squeezed between the mating profile 210and the elastomeric seal 1802. Elastomeric seal 1804 can be locatedinside of the neck rim 208, so that when the foot 106 is pulled onto theflashing, the mating profile 210 can be pulled down onto the elastomericseal 1804. The various elastomeric seals can each provide additionalbarriers to water ingress.

FIG. 19A is a bottom view of an exemplary rail-less mounting system witha displacement restrictor, and FIG. 19B is a perspective view of theexemplary rail-less mounting system of FIG. 19A with a displacementrestrictor, according to the illustrative embodiment. PV Module 1910 canbe connected via frame 1912 and mounting clips 1904 to roof surface1906. When a snow load is applied to the top surface of module 1910,module 1910 and frame 1912 can bend in such a manner that the center ofmodule 1910 is displaced toward roof surface 1906 as will be apparent tothose skilled in the art. If module 1910 is allowed to bend too far,frame 1912, mounting clip 1904 or the materials of module 1910 can besubjected to strain that is in excess of their respective material'selastic ability and permanent deformation or failure of the material canoccur. However, if the movement of module 1910 is restricted, module1910 will not be displaced to the point of deformation or failure. Anexample of such a method of restriction is shown in FIGS. 19A and 19Bwhere a displacement restrictor 1908 can be placed in the middle ofmodule 1910, between module 1910 and roof surface 1906. Optionallydisplacement restrictor 1908 can be mounted such that it is notpermanently in contact with roof surface 1906, and gap 1920 defines thedistance that the surface of module 1910 can deflect before displacementrestrictor 1908 engages roof surface 1906 and thus provides an opposingforce to snow load and restricts the displacement of module 1910. Aswill be obvious to those skilled in the art, the number of, theconstruction, the material, the position of displacement restrictor 1908as well as the type of expected loading are just some of the variablesthat will define via proper design, gap 1920, and the general shape andsize of displacement restrictor 1908. It will be further appreciatedthat displacement restrictor 1908 can be made from an abundance ofmaterials with associated manufacturing methods. Also, the manner inwhich displacement restrictor 1908 is attached to module 1900 can be viaany binding technique including adhesives, adhesive tape, glues,reclosable fasteners or any other method that can be used to connect theparts. It will also be appreciated that in various embodiments there canbe a number of options that can be varied, such as the number ofdisplacement restrictors 1908, whether the displacement restrictor(s)1908 are optionally connected to roof surface 1906 and/or module 1910,and the optional presence and size of a gap 1920, and these options canbe determined by the specific implementation in each installation, solong as such combination results in the system being able to becertified and withstand relevant loading conditions.

When a plastic or other electrically insulating material frame 1912 isused for the module, it can negate the need for grounding according toUL 2703 since there is no exposed metal in contact with the powerproducing module. This saves the direct material cost and labor ofinstalling bonding means between modules to ensure that they areelectrically connected and then connecting the bonded array to ground.Furthermore, the removal of ground removes the reference voltage orpotential, the main driver of Potential Induced Degradation (PID).Lastly, NEC 2017 Section 690.12 requires all PV systems to operate witha rapid shutoff device that will disconnect individual PV modules fromthe system thus making it safe for personnel, especially firefighters,to be able to touch the grounded parts of the system without exposure tohigh voltage and current. This specific NEC rule is being adopted intomost state electrical codes. In response to these regulations,electronic manufacturers are selling a rapid shutoff device andinstallers are buying and installing one such system per module. Othercompanies are integrating their shutoff devices with modules. Theserapid shutoff devices further increase the cost of the PV system.According to NEC 2017, when the PV system does not require grounding,i.e. if it has no exposed metal parts connected to the individualmodules, rapid shutoff devices are not required. Therefore, having asystem that does not require grounding will save the direct cost ofshutoff devices and installation labor.

An alternative system that can be NEC 2017 compliant without (free of)the use of a plastic frame can use frameless modules. These have becomemore available on the market and in order to handle the required loads,can be glass-on-glass modules as opposed to the ubiquitousglass-on-backsheet modules as will be appreciated by those skilled inthe art. Unfortunately, most installers still utilize some form of metalor other electrically conductive material to mount these systems on theroof. Since the mounting clips are “in direct contact” with the powerproducing module, these systems still require grounding, negating allthe benefits as described above. The system described herein can removethe need for grounding from frameless modules by utilizingnon-electrically conductive materials such as plastic for the clips andthe rest of the mounting hardware as previously described. Asillustrated in FIGS. 8-11, the flexibility of the clip design can allowfor any shape to mate with the purposed designed clip, includingframeless and glass-on-glass modules.

The advantages of a quick release system should be apparent to thoseskilled in the art. Being able to remove modules quickly formaintenance, to fix or replace equipment and or to replace the roof areobvious advantages. However, the system described here further providesanother benefit of quick release systems: reducing the fire setbackrequirement in the International Fire Code (IFC 605.11) that is beingadopted by many states.

To illustrate the advantage that can be attained by a quick releasemechanism to reduce fire setbacks, refer to the illustrative example inFIGS. 20A and 20B. FIG. 20A is a perspective view of a building andsloped rooftop with standard fire setbacks, according to the prior art;and FIG. 20B is a perspective view of an exemplary building and slopedrooftop with reduced fire setbacks, according to an illustrativeembodiment.

FIG. 20A illustrates the setbacks required on a roof according to IFC605.11. Side setback 2002 is required to be 3 feet from the edge of theroof according to IFC Section 505.11.1.2.3. This requirement has beenincorporated into numerous building and electrical codes including NEC2017. Side setback 2002 is required for firefighter access to the roofin order for the personnel to be able to get to the apex of the roof andcreate a vent hole for the fire raging inside the house. Fireventilation holes and their positioning should be obvious to thoseskilled in the art. Side setback 2002 is required no matter the layoutof the roof, even when there is ample access from the other directionsof the roof. Apex setback 2004 is required so that a ventilation holefor smoke can be created. However, fire fighters prefer to create thehole directly above the fire since there might be a case where air inthe top space of the roof is not directly connected to the air above thefire. Both side setback 2002 and apex setback 2004 limit the size of PVArray 2006. As can be seen in FIG. 20A, PV Array 2006 is bounded by a 3foot setback from the edges of the roof sans the eave. With 3 feet beingalmost the width of a module, this means that in a portrait installationtwo extra columns of modules can be installed. In a landscapeinstallation orientation one extra column can be added. Furthermore ifapex setback 2004 can be eliminated, there will be more space foroptimizing the layout of the array and another row of modules could beadded.

When a quick release system is utilized by the mounting system of PVArray 2006, firefighters will be able to remove PV modules as they scalethe roof. Furthermore, firefighters can remove PV modules above theoptimal point to make a ventilation hole, and in creating that hole, beable to better contain and control the fire. Thus it is highly desirableto be able to utilize quick release systems.

For PV array 2006, having quick release systems means that local firedepartments can train their personnel to utilize the quick releasesystem and can decide that additional roof access is not required whensuch a system is in place. This will allow system designers to utilizethe entire roof space to create an optimal PV array 2010, as shown inFIG. 20B. For system installers, this means a larger system can beinstalled on the roof. Since cost of sales is an indirect cost, the $/Wof this cost drops with systems because the cost remains the same butthe system's size in W increases.

The foregoing has been a detailed description of illustrativeembodiments of the invention. Various modifications and additions can bemade without departing from the spirit and scope of this invention.Features of each of the various embodiments described above may becombined with features of other described embodiments as appropriate inorder to provide a multiplicity of feature combinations in associatednew embodiments. Furthermore, while the foregoing describes a number ofseparate embodiments of the apparatus and method of the presentinvention, what has been described herein is merely illustrative of theapplication of the principles of the present invention. For example, aratchet system utilizing geared teeth that are engaged with anengagement system can be utilized instead of the adjusting nut and bolt.Also, as used herein, various directional and orientational terms (andgrammatical variations thereof) such as “vertical”, “horizontal”, “up”,“down”, “bottom”, “top”, “side”, “front”, “rear”, “left”, “right”,“forward”, “rearward”, and the like, are used only as relativeconventions and not as absolute orientations with respect to a fixedcoordinate system, such as the acting direction of gravity.Additionally, where the term “substantially” or “approximately” isemployed with respect to a given measurement, value or characteristic,it refers to a quantity that is within a normal operating range toachieve desired results, but that includes some variability due toinherent inaccuracy and error within the allowed tolerances (e.g. 1-2%)of the system. Accordingly, this description is meant to be taken onlyby way of example, and not to otherwise limit the scope of thisinvention.

What is claimed is:
 1. A method for installing a solar module comprisingthe steps of: engaging a mounting base into a snap-in groove of anadjustable foot; sliding the mounting base within the snap-in groove ofthe adjustable foot to position the mounting base in a desired locationalong the adjustable foot; pressing the mounting base into theadjustable foot, so that the mounting base disengages from the snap-ingroove and so that a mounting base engagement feature is pressed intoengagement with a foot engagement feature, thereby securing the mountingbase to the adjustable foot; and attaching the solar module to amounting clip attached to a mounting post associated with the mountingbase.
 2. The method of claim 1, further comprising: turning anadjustment screw that connects the mounting post to the mounting base,so that the height of the mounting post is adjusted relative to theadjustable foot after the module has been attached to the mounting clip.3. The method of claim 1, further comprising: installing a flashing on ashingle on a roof, the flashing having a clearing hole; aligning a bolthole in the adjustable foot with the clearing hole; and installing abolt through the bolt hole in the adjustable foot, through the clearinghole, and into the roof.
 4. The method of claim 1, wherein the step ofattaching the solar module to the mounting clip further comprisesattaching the solar laminate to a frame to form a module, and attachingthe frame to the mounting clip.
 5. The method of claim 1, furthercomprising releasing the solar module from attachment to the mountingclip by applying a vector force to a fast-release mechanism on themounting clip.
 6. The method of claim 1, further comprising releasingthe solar module from attachment to the mounting base by applying avector force to the mounting base to release it from the snap-in grooveon the foot and allowing the foot to be removed from the mounting base.7. The method of claim 1 wherein the mounting post is adjustably engagedwith respect to the mounting base.